Sol-gel processing and characterization of (RE-Y)-zirconia powders for thermal barrier coatings

The effect of doping on the structural, morphological and thermal properties of ZrO₂-XO_1.5 (X = Y, La, Sm, Er) solid solutions for thermal barrier (TBC) applications was investigated. Oxide powders of various compositions from 9.7 to 40 mol% XO_1.5 (X = Y, La, Sm, Er) were synthesised by the sol-gel route. The structural analysis of the powders was performed using X-ray diffraction analysis coupled with Rietveld refinements and the measurement of their specific surface area with the BET method. For each rare earth dopant, the morphology of the powders varies from monoliths to agglomerates of thinner particles when the doping amount increases. In order to determine the specific heat, the thermal diffusivity at room temperature and the thermal expansion coefficient of some selected compositions, DSC, laser thermal diffusivity and high-temperature dilatometry measurements were performed on samples densified by Spark Plasma Sintering. Working thermal characterisation indicated that zirconia doped with 30 mol% SmO_1.5 and ErO_1.5 have better insulation properties and a lower thermal expansion coefficient than our reference YSZ ceramic. These various compositions are very promising for the elaboration of multilayer TBCs by the sol-gel process.